Aerosol-forming member

ABSTRACT

An aerosol-forming member for an aerosol delivery device is disclosed. The aerosol-forming member comprises a sheet of material configured to heat and wick a solution. The sheet of material comprises at least one corrugation.

RELATED APPLICATIONS

The present application is a National Phase entry of PCT Application No.PCT/GB2015/050195, filed on 28 Jan. 2015, which claims priority to GBPatent Application No. 1401520.2, filed on 29 Jan. 2014, which arehereby fully incorporated herein by reference.

TECHNICAL FIELD

The disclosure relates to an aerosol-forming member for an aerosoldelivery device. The disclosure also relates to an aerosol deliverydevice component comprising the aerosol-forming member, and an aerosoldelivery device comprising said aerosol delivery device component.

BACKGROUND

An aerosol delivery device is a device used for delivering substancesinto the body via the lungs. One type of aerosol delivery device forms avapor of a solution in which the substances are dissolved. This vaporcondenses within the aerosol delivery device as it mixes with air so asto form droplets or aerosol which is suitable for inhalation. Theseaerosol delivery devices may comprise a heating element that isconfigured to evaporate the solution held within the aerosol deliverydevice so as to form said aerosol. Alternatively, some aerosol deliverydevices may utilize piezo atomizers to generate the aerosol.

SUMMARY

According to the disclosure, there is provided an aerosol-forming membercomprising a sheet of material configured to heat and wick a solution,wherein the sheet of material comprises at least one corrugation.

In one embodiment, the sheet of material may comprise a capillarystructure configured to wick a solution.

The capillary structure may be exposed on both sides of the sheet ofmaterial. The capillary structure may extend throughout the whole sheetof material. The sheet of material may be heatable. The capillarystructure may be made of an (electrically) heatable material.

In an alternative embodiment, the sheet of material may comprise a firstlayer that is heatable and a second layer comprising a capillarystructure.

The sheet of material may comprise a peak and a trough, with saidpeaks/troughs being either rounded or pointed, i.e. where the sheet ofmaterial includes corrugations forming vertices.

Alternatively, the sheet of material may have a wave form.

According to another aspect, there is provided an aerosol deliverydevice component comprising an air inlet and an air outlet fluidlycommunicating via an aerosol chamber defined by chamber walls, and anaerosol-forming member as described above, the aerosol forming memberbeing located at least partially within the aerosol chamber.

In one embodiment, the aerosol delivery device component may furthercomprise an aerosol-forming member located completely in the aerosolchamber.

In one embodiment, the sheet of material may comprise two opposing majorsurfaces that are aligned with a direction of flow of air through theaerosol chamber.

In another embodiment, the sheet of material may comprise two opposingends that are attached to the aerosol delivery device component suchthat the sheet of material is suspended across the aerosol chamber.

The aerosol forming member may be attached to at least one of thechamber walls.

In one embodiment, one of the chamber walls is a printed circuit boardand the aerosol-forming member is attached to the printed circuit board.

In one embodiment, the at least one corrugation of the sheet of materialmay be in close proximity to at least one of the chamber walls.

In one embodiment, the at least one corrugation of the sheet of materialmay be in contact with at least one of the chamber walls.

At least one of the chamber walls may comprise a heat shield.

According to yet another aspect, there is provided an aerosol deliverydevice component comprising an air inlet and an air outlet fluidlycommunicating via an aerosol chamber defined by chamber walls, whereinat least one of the chamber walls comprises a liquid reservoir matrix.

The liquid reservoir matrix may comprise a capillary structure.

In one embodiment, the liquid reservoir matrix may comprise a heatresistant layer and a resilient layer.

In another embodiment, two opposing chamber walls may each comprise aliquid reservoir matrix, and the heat resistant layer of each liquidreservoir matrix is innermost relative to the aerosol chamber such thatthe resilient layer urges the heat resistant layers towards one another.

The aerosol delivery device component may further comprise anaerosol-forming member located at least partially within the aerosolchamber. In one embodiment, the aerosol delivery device component mayfurther comprise an aerosol-forming member located completely within theaerosol chamber.

In one embodiment, the aerosol-forming member may comprise any of thefeatures described above.

The at least one corrugation of the sheet of material may be in contactwith the liquid reservoir matrix.

According to a further aspect, there is provided an aerosol deliverydevice comprising an aerosol delivery device component and/or aerosolforming member as described above.

According to another aspect, there is provided an aerosol-forming membercomprising a sheet of material configured to heat and wick a solution,wherein the sheet of material has a cross-sectional profile having atleast one point of inflection.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments will now be described, by way of example only, withreference to the accompanying drawings in which:

FIG. 1a shows a cross-sectional side view of an aerosol delivery devicecomprising an aerosol-forming member according to an embodiment.

FIG. 1b shows a cross-sectional side view of an alternative aerosoldelivery device comprising an aerosol-forming member according to anembodiment.

FIG. 2a shows a cross-sectional side view of a detachable component,which may be used in the device of FIG. 1a , comprising anaerosol-forming member according to an embodiment.

FIG. 2b shows a cross-sectional view of the aerosol delivery devicealong the line X-X of FIG. 2 a.

FIG. 2c shows a cross-sectional view of the aerosol delivery devicealong the line X-X of FIG. 1 b.

FIG. 3a shows a cross-sectional view of another embodiment of theaerosol delivery device.

FIG. 3b shows a cross-sectional view of another embodiment of theaerosol delivery device.

DETAILED DESCRIPTION

Referring now to FIG. 1a , an aerosol delivery device 1 according to anembodiment is disclosed. The aerosol delivery device comprises anaerosol delivery device component 1′, and an energy store component 1″.The aerosol delivery device component 1′ is removably attachable to theenergy store component 1″, however it is envisaged that in analternative embodiment, the aerosol delivery device component 1′ and theenergy store component 1″ are inseparable such that they form a singlecomponent.

The aerosol delivery device component 1′ may be disposable and theenergy store component 1″ may be reusable. However, it is envisaged thatwhen the two components are formed as a single component then theaerosol delivery device may be disposable or reusable.

The energy source component 1″ comprises a housing holding a battery 30and an electric circuitry 31 as shown in FIG. 1a . It should beappreciated that an alternative power source to a battery may be used.

The aerosol delivery device component 1′ is shown in greater detail inFIG. 2a and it comprises a housing 2 formed with a mouthpiece 3 at oneend and an attachment end formed with a connecting passage 35 at theopposite end. The connecting passage 35 electrically connects componentsheld in the aerosol delivery device component 1′ with the battery 15disposed in the energy store component 1″ via the electric circuitry 31(not shown).

The housing 2 is further formed with an air passage extending throughthe aerosol delivery device component 1′. The air passage comprises anair inlet 5, plenum chamber 4, chamber inlet 33, aerosol chamber 6,chamber outlet 28 and outlet aperture 7. In use air is drawn in throughthe air inlet 5, into the plenum chamber 4, then to the chamber inlet 33which supplies the air into the aerosol chamber 6, the air then exitsthe aerosol chamber 6 via chamber outlet 28 and leaves the aerosoldelivery device component 1′ via the outlet aperture 7 formed in themouthpiece 3.

FIG. 2b illustrates a cross-sectional view of the aerosol deliverydevice component 1′ along line X-X shown in FIG. 2a . As can be seen inFIG. 2b , the aerosol chamber 6 is located in the center of the housingand is defined by chamber walls. The chamber walls comprise twopartitioning walls 8, a chamber side wall 32 and a support plate 20′ asexplained in more detail below. An aerosol-forming member 10A accordingto an embodiment is located in the aerosol chamber 6. On opposite sidesof each partitioning walls 8 relative to the aerosol chamber 6, are twosolution reservoirs 9 configured to contain a solution. In oneembodiment the support plate 20′ is the PCB. In an alternativeembodiment, the support plate 20′ is integrated with the housing 2 suchthat a capillary gap is formed between the housing and the partitioningwall 8.

According to one embodiment, the aerosol-forming member 10A may comprisea sheet of material having a single layer that is configured to wick andheat a solution. Thus, the sheet of material can absorb solution fromthe solution reservoirs 9 and thereafter heat it up so that itevaporates and forms a vapor. The sheet of material is sheet-like innature. The sheet of material may comprise an open-pored structure, foamstructure, mesh structure or interconnecting network of pores, all ofwhich form a capillary structure. The capillary structure enables theaerosol-forming member 10A to wick or absorb a solution. The term“capillary structure” used herein is to be understood as a structurethrough which liquid or a solution can travel as a result of capillaryaction.

An embodiment of an alternative aerosol delivery device 1 is shown inFIG. 1b and it comprises a housing 2 with a mouthpiece 3. A passage 4 isprovided in the housing 2 and is open to atmosphere via an air inlet 5.The passage 4 is in fluid communication with an aerosol chamber 6 whichin turn is in fluid communication with an outlet aperture 7 formed inthe mouthpiece 3. Therefore, in use, air may be drawn through the airinlet 5 and into the aerosol chamber 6, via the passage 4, and thenthrough the outlet aperture 7 as is indicated by the arrows in FIG. 1.

Referring now to FIG. 2c which shows a cross-sectional view of theaerosol delivery device 1 of FIG. 1b , a space is provided inside thehousing 2 which is divided by a partitioning wall 8 into the aerosolchamber 6 and a liquid reservoir 9 that contains a solution. The aerosolchamber 6 is defined by the partitioning wall 8, a support plate 19 anda heat shield 26. The partitioning wall 8, support plate 19 and heatshield 26 act as chamber walls. Two capillary gaps 17, 18 are formedbetween the ends 20, 21 of the partitioning wall 8 and the support plate19. For the avoidance of doubt, the device shown in FIG. 1 may alsoinclude a similar heat shield as necessary. In one embodiment thesupport plate 19 is the PCB. In an alternative embodiment, the supportplate 19 is integrated with the housing 2 such that a capillary gap isformed between the housing and the partitioning wall 8.

An aerosol-forming member 10 a according to an embodiment is located inthe aerosol chamber 6 as seen in FIG. 2b or 2 c. The aerosol-formingmember 10 a comprises a sheet of configured to have corrugations 10 bsuch that it comprises peaks and troughs. In the present application, acorrugation is to be understood as two bends, or a peak and a trough, ora ridge and a groove. The sheet of material may also be described ashaving a cross-sectional profile comprising at least one point ofinflection.

The corrugations of the aerosol-forming members 10 a may follow ameandering or oscillating path, or a sine curve or any other similarpattern. The aerosol-forming member 10 a may comprise regularcorrugations such that it comprises a repetition of identicalcorrugations as seen in FIG. 2. However, in an alternativeun-illustrated embodiment the aerosol-forming member may compriseirregular corrugations wherein the shape of the peaks and troughs differfrom one another. Although FIGS. 2a and 2b show an aerosol-formingmember 10 a comprising rounded corrugations 10 b, i.e. rounded peaks andtroughs, it should be understood that the disclosure is not limitedthereto, but also includes corrugations forming vertices (formingzig-zag like corrugations). These vertices may have obtuse, acute and/orright angles. Such an arrangement is shown in the embodiment of FIG. 3b(the description of the corresponding reference numerals for theembodiment of FIG. 3a applying also to the embodiment of FIG. 3b ).

The sheet of material may comprise a single layer that is sheet-like innature and comprises two major opposing surfaces 13, 14 and two opposingends 15, 16. The two opposing ends 15, 16 are attached to a supportplate 19 (according to the device of FIG. 1b ) or support plate 20′(according to the device of FIG. 1a ) such that they locate incorresponding capillary gaps 17, 18 formed between the support plate 19,20′ and the ends 21, 20 (according to the device of FIG. 1 b) of thepartitioning wall 8. In an embodiment the two opposing ends 15, 16 arealso electrically connected to the support plate 19. The support plate19 may be a printed circuit board (PCB). The sheet of material isconfigured to extend in a contact-free manner across the aerosol chamber6 such that the aerosol-forming member 10 a is suspended across theaerosol chamber 6 and only the ends 15, 16 of the aerosol-forming member10 a are in contact with the chamber walls of the aerosol chamber 6.This configuration reduces undesired loss in heat conduction of theaerosol-forming member 10 a. As a result, the aerosol-forming member 10a can heat up faster to a sufficient temperature wherein a solution heldin the aerosol-forming member evaporates than if the aerosol-formingmember was in continuous contact with the chamber walls. It should beunderstood that the sheet of material does not have to be a singlelayer, but can be a sheet of multiple layers of the same or differentmaterial that are layered/laminated/attached so as to form the finalsheet-like material.

In one embodiment, the aerosol-forming member 10 a has corrugations suchthat it extends substantially across the entire cross-section of theaerosol chamber 6 as seen in FIGS. 2b,c and 3 a,b. More specifically,the aerosol-forming member 10 a does not only extend in a directionbetween the capillary gaps 17, 18, but also extends across substantiallythe whole distance between the support plate 19 and the partitioningwall 8/heat shield 26 (according to the embodiment of FIG. 2c ), andacross substantially the whole distance between the support plate 20′and the chamber wall 32/heat shield 26 (according to the embodiment ofFIG. 2b ). Thus, in these embodiments, the corrugations 10 b areadjacent or in close proximity to the chamber walls, or morespecifically the wall 8, 32, the heat shield 26 and the support plate19,20′. In another embodiment, the aerosol-forming member 10 a extendsacross the aerosol chamber 6 to such an extent that the corrugations 10b contact or engage with the chamber walls (as shown in FIGS. 3a and 3b). In yet another embodiment, the depth of the corrugations 10 b isshorter such that the aerosol-forming member 10 a does not extend acrossthe whole distance between the support plate 19 and the partitioningwall 8/heat shield 26 (according to the embodiment of FIG. 2c ), or theaerosol-forming member 10 a does not extend across the whole distancebetween the support plate 20′ and the wall 32/heat shield 26 (accordingto the embodiment of FIG. 2b ). It is not necessary that each of thecorrugations 10 b contact or be in close proximity with the chamberwalls. Where there are multiple corrugations, each corrugation may beindependently configured to either be in contact with the chamber walls,be in close proximity with the chamber walls, or to be distanced fromthe chamber walls.

The sheet of material, which may comprise a single layer, is configuredto wick and heat a solution such that the sheet of material can absorbsolution and thereafter heat it up such that it evaporates and forms avapor. The sheet of material may comprise an open-pored structure, foamstructure or interconnecting network of pores, all of which form acapillary structure. The capillary structure enables the aerosol-formingmember 10 a to wick or absorb a solution. The term “capillary structure”used herein is to be understood as a structure through which liquid or asolution can travel as a result of capillary action.

The aerosol-forming member 10 a may be made of a porous granular,fibrous or flocculent sintered metal(s) so as to form said capillarystructure. In another embodiment, the aerosol-forming member 10 acomprises an open-pored metallic foam or a group of layers of wire meshor calendered wire mesh or wire fabric which also forms a capillarystructure. The aerosol-forming member 10 a may be formed from stainlesssteel, e.g. AISI 304 or 316, or from a heating conductor alloy, likenickel chromium alloys.

Furthermore, the aerosol forming member 10 a may be formed with acapillary structure that extends throughout the whole aerosol-formingmember 10 a such that it is exposed on the two major surfaces 13, 14 ofthe sheet of material. In this embodiment each of the major surfaceswould be exposed to the chamber 6. Alternatively, one of the majorsurfaces 13, 14 may optionally be sealed with a metallic foil or coverthat is sintered or attached to said major surface such that saidsurface is vapor impermeable. Alternatively, a region of one or both ofthe major surfaces 13, 14 may be sealed so as to be vapor impermeable.In another embodiment, the aerosol-forming member 10 a is configuredsuch that the capillary structure does not extend throughout the wholeaerosol-forming member. For example, in one embodiment the capillarystructure does not extend to one of the major surfaces 13, 14 such thatthere is no exposed capillary structure in this area. Alternatively thecapillary structure is exposed on a region of one or both major surfaces13, 14. In the context of the present disclosure, reference to“exposure” of the capillary surface does so with reference to thechamber 6 and it is possible that there are areas of the capillarysurface that extend to the major surfaces 13, 14 but that are covered byother components of the device.

In yet another un-illustrated embodiment, a thin support layer may beattached to one or both of the major surfaces 13, 14. Such a supportlayer provides stability to the sheet of material. The support layer maybe formed from a wire mesh or from individual wires and may be made ofstainless steel.

The material from which the aerosol-forming member 10 a is formed isheatable in that it comprises sufficient electrical resistivity so thatwhen current is passed through, the aerosol-forming member 10 a heats upto a temperature sufficient to cause the solution held in the capillarystructure to evaporate or vaporize. In these embodiments, theaerosol-forming member 10 a can be considered to comprise a heatingelement formed with a capillary structure such that the heating elementand the capillary structure are integrated and form a single entity orunit.

In the above described embodiments wherein the sheet of materialcomprises a single layer configured to wick and heat a solution, thesheet of material can be described as comprising a heating element and awick that are arranged in the same surface.

In an alternative un-illustrated embodiment, the sheet of material maycomprise a plurality of layers, for example it may comprise anycombination of the aforementioned structures and materials, e.g. byproviding multiple layers of different structures/materials, the layersbeing joined together, e.g. by sintering. One such alternativeun-illustrated embodiment will now be described in more detail.

This un-illustrated alternative aerosol-forming member comprises a sheetof material that is sheet-like in nature and formed from a plurality oflayers. For example, the aerosol-forming member 10 a may comprise afirst heatable layer acting as a heating element. The first layer isformed from a material that is configured to be heated up and maycomprise a metal wire mesh, it may be made of stainless steel or nickelchromium alloys. The aerosol-forming member 10 a may further comprise asecond layer formed with an open-pored structure, foam structure orinterconnecting network of pores, all of which form a capillarystructure. The capillary structure enables the aerosol-forming member 10a to wick or absorb a solution. This second layer may comprise a fiberweb or fabric made of glass fibers, glass fiber yarns or any othernon-conductive and inert, thus relatively non-heatable (electricallynon-heatable) fiber materials. In this embodiment the sheet of materialcan be described as comprising a heating element and a wick that arearranged in parallel surfaces and are connected to each other. Thesecond layer acts as a wick.

The first layer (heating element) and the second layer (wick formed witha capillary structure) are laid on top of each other so as to form asheet of material having two opposing major surfaces, wherein thecapillary structure is exposed on one or both major surfaces (dependingon the configuration of the heating element).

In an alternative un-illustrated embodiment, the sheet of materialcomprises a third layer that is similar to the second layer in that itcomprises a capillary structure. The second and the third layer sandwichthe first layer such that the capillary structure is exposed on bothmajor surfaces of the sheet of material.

In the embodiments wherein the sheet of material is formed from aplurality of layers as described above, the first layer forming theheating element and the second and/or third layer(s) forming the wickare parallel and connected to each other. The layers may be connected toeach other by mechanical, chemical or thermal means. In one embodiment,the layers are sintered or fritted to one another.

It should be understood that the present disclosure wherein the sheet ofmaterial comprises a plurality of layers is not limited to the examplesdescribed above. For example, in an alternative embodiment both thefirst and the second layers may be made of a heatable material. Forinstance, the first layer may comprise a metal foil, and the secondlayer may be made of a porous granular, fibrous or flocculent sinteredmetal(s) or comprise an open-pored metallic foam or a wire meshstructure all of which form said capillary structure. The first andsecond layers may be formed from stainless steel and may be sinteredtogether. In this embodiment the sheet of material can be described ascomprising a heating element and a wick that are arranged in the samesurface and in parallel surfaces, the capillary structure being onlyexposed on one of the major surfaces of the sheet of material.

In another embodiment, the first and second layers may be made of porousheatable material(s), such that both layers are configured to heat andwick a solution. In this embodiment the sheet of material can bedescribed as comprising a heating element and a wick that are arrangedin the same surface and in parallel surfaces.

In a further alternative un-illustrated embodiment, the sheet ofmaterial comprises a porous first layer having small sized pores and asecond porous layer having larger sized pores than the first layer, thusboth layers are formed with a capillary structure however the secondlayer forming the inner major surface can emit more vapor than the firstlayer forming the outer major surface. At least one of the two layers isformed from a heatable material as described above. Both layers may beformed with a structure and material as discussed above in relation tothe capillary structure.

The sheet of material according to any of the above describedembodiments has a thickness or depth that falls within the range of20-500 μm. Alternatively, the thickness falls within the range of 50 to200 μm. The thickness or depth should be understood as meaning thedistance between the two major surfaces 13, 14 of the sheet of material.

The ends 21, 20 of the partitioning wall 8 (according to the embodimentof FIG. 2c ) are formed with two supply passages 22 such that thereservoir 9 and capillary gaps 17, 18 are in fluid communication. Thesupply passages are of a width sufficient to achieve a capillary effect.Therefore, in use, a solution held in the reservoir 9 moves by capillaryaction from the fluid reservoir 9 into the supply passages 22 towardsthe capillary gaps 17, 18, and then from the capillary gaps 17, 18 tothe capillary structure at the ends 15, 16 of the aerosol-forming member10 a. The capillary structure of the aerosol-forming member 10 aprovides a capillary effect similar to a wick, thus the capillarystructure enables the aerosol-forming member 10 a to absorb the solutionprovided to the capillary gaps 17, 18 such that the solution isdistributed throughout the whole capillary structure of the sheet ofmaterial.

The embodiment of FIG. 2b operates in a similar manner, except theaerosol-forming member 10 a is fed from reservoir 9 via capillary gaps17, 18.

It should be understood that the present disclosure is not limited totwo capillary gaps 17, 18, but may comprise only a single capillary gapfeeding only one of the ends 15,16 of the aerosol-forming member 10 a.

A battery 30 controlled by a controller forming part of a printedcircuit board (PCB) is disposed in the housing 2 as seen in FIG. 1, andthe ends 15, 16 of the aerosol-forming member 10 a are electricallyconnected, e.g. via circuitry, to the positive and negative terminals ofthe battery 30 respectively. When current is drawn from the battery 30and through the sheet of material, the resistance of the sheet ofmaterial causes it to increase in temperature. In the embodiment whereinthe sheet of material comprises a non-porous heatable first layer, forinstance a metal foil, and where the outer major surface is formed fromsaid first layer, the resistance of said first layer causes the firstlayer acting as a heating element to increase in temperature, the firstlayer in turn heating up adjacent second and/or third layers includingthe solution contained/stored in the pores/void of the capillarystructure of said second and/or third layers. The current drawn by thebattery 30, and thus the temperature of the sheet of material may becontrolled by a switching circuit, e.g. a Power-MOSFET switchingcircuit, within the housing 2. The switching circuit may provideautomatic control of the temperature, for example, by using temperaturesensors (not shown), or may be controlled by a button or dial (notshown) provided on the housing 2 that may be manipulated by the user.

In one embodiment the partitioning wall 8 may be provided with a heatshield 26 on a surface facing the aerosol-forming member 10 a. The heatshield 26 is shown in FIG. 2b and it protects the partitioning wall 8from overheating as the temperature of the aerosol-forming member 10 ais increased. The heat shield 26 may be formed from a thinnon-conductive material like oxidized stainless steel wire mesh or inertfabrics like glass or carbon fabrics. It should be understood that theheat shield 26 is optional.

Operation of the aerosol delivery device will now be described withreference to FIGS. 1 and 2. In use, the user may manually activate theaerosol delivery device 1 or the aerosol delivery device 1 may beactivated automatically as the user starts puffing on the aerosoldelivery device 1. This may be achieved by a pressure sensor (not shown)included in the electric circuitry 31 and communicating with the inletpassage/plenum chamber 4 via a connecting passage. In either embodiment,the battery 30 provides a potential difference between the opposing ends15, 16 of the aerosol-forming member 10 a as the aerosol delivery deviceis activated, causing current to flow though the sheet of material suchthat the member 10 a increases in temperature. This increase intemperature causes the solution held in the capillary structure of thesheet of material to evaporate so as to form a vapor. The evaporatedsolution mixes with the air drawn into the aerosol delivery device viapassage 4 by the user. The evaporated solution mixes with air in theaerosol chamber 6, and as this occurs the vapor condenses and formsdroplets such that an inhalable aerosol is produced.

The aerosol-forming member according to any of the above describedembodiments is located in the housing 2 such that the planes of themajor surfaces 13, 14 are parallel to or substantially aligned with thedirection of the airflow through the aerosol chamber 6. Thus, when asolution is held in the aerosol-forming member 10 a and it is heated upsuch that the solution evaporates, the solution evaporates in adirection transverse to the direction of the airflow. In the embodimentswherein the capillary structure is exposed on both sides of the sheet ofmaterial, the solution is evaporated from both sides in oppositedirections. The corrugations 10 b of the sheet of material form channels25 through which air flows and also in which a solution is evaporatedsuch that when it mixes with airflow aerosol is formed. Thus, thecorrugations 10 b or channels 25 direct the flow of aerosol through theaerosol delivery device towards the user. Furthermore, as a result ofthe corrugations 10 b, solution is evaporated from the major surfaces13, 14 in a direction towards another region of the major surfaces 13,14 which results in reduced levels of aerosol condensing on the chamberwalls and other internal components. Furthermore, as vapor is emittedfrom the major surfaces 13, 14 towards another region of the same majorsurface, vapor density is increased. Additionally, as theaerosol-forming member cools down aerosol and vapor remaining in theaerosol chamber 6 that condenses onto one of the major surfaces 13, 14will be reabsorbed into the capillary structure of the aerosol-formingmember and re-evaporated as the aerosol-forming member heats up again.Condensate formed on the chamber walls may at least partially bereabsorbed into the capillary structure via the corrugations 10 b.

As previously described, the corrugated configuration reducescondensation from forming and accumulating on the chamber walls,internal components and/or inner walls of the housing 2. Thus, spongesor other means for absorbing condensation not inhaled by the user thatare used in some conventional aerosol delivery devices may be omitted.This results in a more compact aerosol delivery device 1, as well as asimplified manufacturing process and reduced costs. Furthermore, byreducing the amount of aerosol and vapor from condensing onto innerwalls of the housing 2, the transfer of condensation heat to the housing2 may be reduced, making the aerosol delivery device 1 more comfortablefor the user to hold.

After the aerosol-forming member 10 a has been activated and aerosol hasformed in the channels 25, the aerosol is drawn through the channels 25as the user continues to inhale. The aerosol then exits the aerosolchamber 6 through a chamber outlet 31 provided in the housing 2 as seenin FIG. 1b . The aerosol then passes through an optional aerosolrefining member 32 provided in the housing 2, causing the aerosol to becooled. The refining member 32 may also contain flavoring agents likementhol that are released into the flow of aerosol before entering theuser's mouth via the outlet 7 provided in the mouthpiece 3. Meanwhile,the solution that has evaporated from the capillary structure of thesheet of material is replaced by fresh solution from the reservoir 9 dueto the capillary effect of the capillary gaps 17, 18 and the capillarystructure of the aerosol-forming member 10 a as described above andfresh air enters the channels 25 via the air inlet 5 and passage 4. Inone embodiment, a pressure drop element/flow resistor 33 is positionedin the passage 4 so that the flow of air into the aerosol chamber 6 canbe controlled. The flow resistor 33 may consist of a simple aperture orhole and may be identical with the air inlet 5 in the housing 2.Alternatively, the flow resistor 33 may consist of a porous body similarto a cigarette filter providing the flow resistance of a conventionalcigarette.

The valve 33 may be controlled by the PCB or manually, for example, byadjusting a switch or dial (not shown) on the housing 2 of the aerosoldelivery device 1.

The degree of corrugation can be varied by varying the number ofcorrugations per distance unit. For example, in one embodiment the sheetof material comprises three corrugations per distance unit. In anotherembodiment the sheet of material comprises 6 corrugations per distanceunit. The greater the degree of corrugation the more aerosol isgenerated by the aerosol-forming member per inhalation.

It should be understood that due to the corrugations of the abovedescribed embodiments, the aerosol-forming member has larger surfacearea compared to a flat aerosol-forming member. Advantageously, thisincreases the efficiency of the aerosol forming member 10 a in that itcan produce more aerosol per inhalation. Furthermore, due to thecorrugation of the aerosol-forming member 10 a, the aerosol deliverydevice 1 can be made more compact.

Referring now to FIG. 3a , another embodiment of an aerosol deliverydevice 51 is disclosed. FIG. 3a shows a cross-section of an aerosoldelivery device 51 similar to the aerosol delivery device 1 shown inFIG. 1a . The aerosol delivery device 51 comprises a housing 52 with amouthpiece (not shown). A passage (not shown) is provided in the housing52 and is open to atmosphere via an air inlet (not shown). The passageis in fluid communication with an aerosol chamber 56 which in turn is influid communication with an outlet aperture (not shown) formed in themouthpiece. Therefore, in use, air may be drawn through the passage andinto the aerosol chamber 56, via the passage, and then through theoutlet aperture similar to the airflow of the aerosol delivery deviceshown in FIG. 1 a.

An aerosol-forming member 60 a is located in the aerosol chamber 56 asseen in FIG. 3a . The aerosol-forming member 60 a comprises a sheet ofmaterial having corrugations 60 b such that it forms peaks and troughs.A corrugation is to be understood as two bends, or a peak and a trough,or a ridge and a groove. The sheet of material may also be described ashaving a cross-sectional profile comprising at least one point ofinflection.

The corrugations may follow a meandering or oscillating path, or a sinecurve, or a zigzag-like configuration, or any other similar pattern. Theaerosol-forming member 60 a may comprise regular corrugations such thatit comprises a repetition of identical corrugations as seen in FIG. 3a .However, in an alternative un-illustrated embodiment the aerosol-formingmember may comprise irregular corrugations wherein the shape of peaksand troughs differ from one another. Although FIG. 3a shows anaerosol-forming member 60 a comprising rounded corrugations 60 b, i.e.rounded peaks and troughs, it should be understood that the disclosureis not limited thereto, but also includes corrugations forming vertices.These vertices may have obtuse, acute and/or right angles. Thisembodiment is shown in FIG. 3b and the reference numerals of FIG. 3aapply correspondingly to the components of FIG. 3 b.

The aerosol-forming member 60 a is similar to the embodiments of theaerosol-forming member 10 a described above with reference to FIGS. 1and 2 and so a detailed description will be omitted. However, it shouldbe understood that the aerosol-forming member 60 a comprises a sheetmaterial having two opposing major surfaces 66, 67. The aerosol-formingmember 60 a has an open-pored structure, foam structure orinterconnecting network of pores, all of which form a capillarystructure. The capillary structure enables the aerosol-forming member 60a to wick or absorb a solution. The sheet of material may comprise asingle or a plurality of layers according to the various embodimentsdescribed with reference to FIG. 2.

The aerosol chamber 56 is defined by chamber walls comprising twoopposing chamber side walls 53, 54 and two opposing chamber main walls57 a, 57 b. The chamber main walls 57 a, 57 b comprise a liquidreservoir matrix 58, 59. The liquid reservoir matrix 58, 59 comprises acapillary structure, for example an interconnecting porous oropen-porous structure, such that it can hold a solution or liquid. Theliquid reservoir matrix 58, 59 comprises a heat resistant layer 62 and aresilient layer 63. The heat resistant layer 62 of each chamber mainwall 57 a, 57 b is exposed to the space of the aerosol chamber 56 andthe resilient layer of each main wall 57 a, 57 b is sandwiched betweenthe heat resistant layer 62 and the housing 52.

The heat resistant layer 62 is sheet-like in nature and comprises one ora plurality of layers that may have a structure of fabric, mesh, wovenfiber web, non-woven fiber web or foam. The heat resistant layer 62 ismade of a heat resistant material, for example, glass, metal,carbon-based materials, ceramic, cotton or heat resistant plastic. Ifthe heat resistant layer 62 is made of metal, the metal may be coated oroxidized so as to prevent short circuits. The heat resistant layer 62 isconfigured to resist heat so that it can withstand heat emitted by theaerosol forming member 60 a and thereby protect the resilient layer 63.

The resilient layer 63 may comprise various structures, for example, itsstructure may be formed from woven fibers, non-woven fibers, foam orsponge. The resilient layer 63 may be made of plastic.

The resilient layer 63 provides a spring force such that it urges orbiases the heat resistant layer 62 towards the corrugations 60 b, i.e.the peaks, troughs or vertices, such that the heat resistant layer 62 ofeach liquid reservoir matrix 58, 59 is in contact with the corrugations,i.e. the peaks, troughs or vertices. This enables the liquid reservoirmatrices 58, 59 to supply solution held therein to the aerosol-formingmember 60 a such that the solution spreads throughout the capillarystructure of the aerosol-forming member 60 a.

The capillarity of the aerosol-forming member 60 a may be greater thanthe capillarity of the reservoir matrices 58, 59, but at least greaterthan the capillarity of the resilient layer 63 so as to induce a flow ofsolution from the liquid reservoir matrices 58, 59 towards theaerosol-forming member 60 a. The capillarity is defined by the pore sizeand the wetting conditions of the respective capillary structures.

It should be understood that the present disclosure is not limited tocomprising two liquid reservoir matrices 58, 59. It may comprise morethan two liquid reservoir matrices. For example, each peak and trough ofa corrugation may be in contact with discrete liquid reservoir matrices.In an alternative embodiment, only one chamber main wall 57 a comprisesa liquid reservoir matrix and the other chamber main wall 57 b is madeof a non-porous material (vice versa).

Ends 64, 65 of the aerosol-forming member 60 a are attached to thechamber side walls 53, 54. In an embodiment both ends 64, 65 of theaerosol-forming member 60 a are attached and can be electricallyconnected to a support plate, which may be a printed circuit board(PCB). Alternatively, ends of the aerosol-forming member 60 a may beattached to one of the heat resistant layers 62 of the chamber mainwalls 57 a, 57 b as seen in FIG. 3. In each embodiment, theaerosol-forming member 60 a is suspended across the aerosol chamber 56.

The aerosol-delivery device 51 further comprises a battery (not shown)and a printed circuit board (PCB) (not shown) as described withreference to FIGS. 1 and 2, and the aerosol-delivery device 51 isconfigured similar to the aerosol delivery device 1 described withreference to FIGS. 1 and 2 such that the ends 64, 65 of theaerosol-forming member 60 a, are electrically connected to the positiveand negative terminals of the battery respectively. When current isdrawn from the battery through the sheet of material of theaerosol-forming member 60 a, the resistance of the sheet of materialcauses it to increase in temperature.

Operation of the aerosol-forming member 60 a will now be described withreference to FIG. 3. Similar to the aerosol-delivery device 1 describedwith reference to FIG. 2, the user may manually activates the aerosoldelivery device 51 or the aerosol delivery device 51 may be activatedautomatically as the user starts puffing on the aerosol delivery device51. This may be achieved by a pressure sensor (not shown) located in thepassage extending between the air inlet and aerosol chamber. In eitherembodiment, the battery provides a potential difference between the ends64, 65 of the aerosol-forming member 60 a as the aerosol delivery device51 is activated, causing current to flow between the ends 64, 65 suchthat the sheet of material increases in temperature. This increase intemperature causes the solution held in the capillary structure of thesheet of material to evaporate so as to form a vapor. The vapor mixeswith air drawn into the aerosol delivery device via passage by the user.The vapor mixes with air in the aerosol chamber 56, and as this occursthe vapor condenses and forms droplets such that an inhalable aerosol isproduced.

The aerosol-forming member according to any of the above describedembodiments with reference to FIG. 3 is located in the housing 52 suchthat the planes of the major surfaces 66, 67 are substantially parallelor aligned with the direction of the airflow. Thus, when a solution isheld in the aerosol-forming member 60 a and it is heated up such thatthe solution evaporates, the solution evaporates in a directiontransverse to the direction of the airflow. In the embodiments whereinthe capillary structure is exposed on both sides of the sheet ofmaterial, the solution is evaporated from both sides in oppositedirections. The corrugations 60 b of the sheet of material form channels68 through which air flows. Furthermore, evaporated solution or vapormixes with the airflow in the channels 68 such that aerosol is formed.Thus, the corrugations 60 b or channels 68 direct the flow of aerosolthrough the aerosol delivery device 51 towards the user. Furthermore, asthe sheet of material comprises corrugations solution is evaporated fromthe major surfaces 66, 67 in a direction towards another region of themajor surfaces which results in reduced levels of aerosol condensing onthe chamber walls and other internal components. Furthermore, as theaerosol-forming member 60 a cools down aerosol and vapor remaining inthe aerosol chamber 56 that condenses onto one of the major surfaces 66,67 will be reabsorbed into the capillary structure of theaerosol-forming member 60 a and re-evaporated as the aerosol-formingmember 60 a heats up again. Condensate formed on the chamber walls mayat least partially be reabsorbed into the capillary structure of theheat resistant layer 62 and that way resupplied to the capillarystructure of the aerosol-forming member 60 a.

Similar to the aerosol-forming member 10 a described with reference toFIG. 2, the corrugated configuration of the aerosol-forming member 60 bshown in FIG. 3 also reduces condensation from forming on the chamberwalls, internal components and/or inner walls of the housing 52. Thus,separate sponges other than the liquid reservoir matrices 58,59 or otherextra means for absorbing condensation not inhaled by the user that areused in some conventional aerosol delivery devices may be omitted. Thisresults in a more compact aerosol delivery device 51, as well as asimplified manufacturing process and reduced costs. Furthermore, byreducing the amount of aerosol from condensing onto the inner walls ofthe housing 52, the transfer of condensation heat to the housing 52 maybe reduced, making the aerosol delivery device 51 more comfortable forthe user to hold.

After the aerosol-forming member 60 a has been activated and aerosol hasformed in the channels 68, the aerosol is drawn through the channels 68as the user continues to inhale. The aerosol then exits the aerosolchamber 56 through a chamber outlet provided in the housing 52. Theaerosol then passes through an optional filter sponge provided in thehousing 52, causing any large particulate in the flow to condense and beremoved from the air flow before entering the user's mouth via theoutlet provided in the mouthpiece. Meanwhile, the solution that hasevaporated from the capillary structure of the sheet of material isreplaced by fresh solution from the liquid reservoir matrices 58, 59 dueto the capillary effect of the capillary structure and the peaks,troughs and/or vertices being in contact with the liquid reservoirmatrices 58, 59. Fresh air enters the channel 68 via the air inlet andpassage. In one embodiment, a flow resistor (as described above) ispositioned in the passage so that the flow of air into the aerosolchamber 56 can be controlled. The valve may be controlled by the PCB ormanually, for example, by adjusting a switch or dial (not shown) on thehousing 52 of the aerosol delivery device 51.

It should be understood that due to the corrugation of the abovedescribed embodiments, the aerosol-forming member has larger surfacearea compared to a flat aerosol-forming member. Advantageously, thisincreases the efficiency of the aerosol forming member 10 a in that itcan produce more aerosol per inhalation. Furthermore, due to thecorrugation of the aerosol-forming member 60 a, the aerosol deliverydevice 51 can be made more compact.

Furthermore, the degree of corrugation of the aerosol-forming member 60a can be changed as described with reference to FIG. 2.

In any of the above mentioned embodiments of the aerosol-forming member,one or both of the ends 15, 16, 64, 65 may be located in line with oroff-set from the peaks, troughs or vertices of the corrugations 10 b, 60b.

In any of the above mentioned embodiments of the aerosol-formingcomponent or device, there may be multiple aerosol-forming members, e.g.two, three, four, five or six aerosol-forming members. Where there aremultiple aerosol-forming members, the number and configuration of thecorrugations on each of the aerosol forming members may be the same ordifferent. Where the number and configuration of the corrugations arethe same, the aerosol-forming members may be positioned in theaerosol-forming component or device such that the corrugations arealigned. Where the multiple aerosol-forming members contain a differentnumber and/or configuration of corrugations, the corrugations that arepresent may still be aligned. For example, two corrugations a firstaerosol-forming member may be aligned with three corrugations of asecond aerosol forming member. Such a configuration would result in thechannels 25, 68 being maintained throughout the aerosol chamber.Alternatively, the multiple aerosol-forming members may be positioned inthe aerosol-forming component or device such that the corrugations areoffset. This may result in better mixing conditions between the vaporand the air and increased aerosol yields. The multiple aerosol formingmembers may be electrically connected in series or in parallel.Furthermore, the multiple aerosol forming members may be controlleddifferently, e.g. heated up sequentially.

The above described embodiments of the aerosol-forming member of theaerosol delivery device 1 are described for use with a solution. Itshould be understood that this solution may comprise certainconstituents or substances that may have a stimulatory effect on theuser. These constituents or substances may be of any kind that issuitable for being delivered via inhalation. The solution in which theconstituents or substances are held or dissolved may primarily consistof water, ethanol, glycerol, propylene glycol or mixtures of theaforementioned solvents. By means of a sufficiently high degree ofdilution in an easily volatile solvent, such as ethanol and/or water,even substances which are otherwise difficult to evaporate can evaporatein a substantially residue-free manner, and thermal decomposition of theliquid material can be avoided or significantly reduced.

In order to address various issues and advance the art, the entirety ofthis disclosure shows by way of illustration various embodiments inwhich that which is claimed may be practiced and provide for superioraerosol-forming member, aerosol delivery device component and aerosoldelivery device. The advantages and features of the disclosure are of arepresentative sample of embodiments only, and are not exhaustive and/orexclusive. They are presented only to assist in understanding and teachthe claimed features. It is to be understood that advantages,embodiments, examples, functions, features, structures, and/or otheraspects of the disclosure are not to be considered limitations on thedisclosure as defined by the claims or limitations on equivalents to theclaims, and that other embodiments may be utilized and modifications maybe made without departing from the scope and/or spirit of thedisclosure. Various embodiments may suitably comprise, consist of, orconsist essentially of, various combinations of the disclosed elements,components, features, parts, steps, means, etc. In addition, thedisclosure includes other inventions not presently claimed, but whichmay be claimed in future.

1. An aerosol-forming member comprising: a sheet of material configuredto heat and wick a solution, wherein the sheet of material comprises atleast one corrugation, so as to provide the sheet a material with across-sectional profile comprising at least one point of inflection. 2.An aerosol-forming member according to claim 1, wherein the sheet ofmaterial comprises a capillary structure configured to wick a solution.3. An aerosol-forming member according to claim 1, wherein the capillarystructure is exposed on both sides of the sheet of material.
 4. Anaerosol-forming member according to claim 1, wherein the capillarystructure extends throughout the whole sheet of material.
 5. Anaerosol-forming member according to claim 1, wherein the sheet ofmaterial comprises a first layer that is heatable and a second layercomprising a capillary structure.
 6. An aerosol-forming member accordingto claim 1, wherein the sheet of material comprises a peak and a trough.7. An aerosol-forming member according to claim 1, wherein the at leastone corrugation forms vertices.
 8. An aerosol-forming member accordingto claim 1, wherein the at least one corrugation is rounded.
 9. Anaerosol delivery device component comprising: an air inlet and an airoutlet fluidly communicating via an aerosol chamber defined by chamberwalls; and an aerosol-forming member according to claim 1, the aerosolforming member being located at least partially within the aerosolchamber.
 10. An aerosol delivery device component according to claim 9,wherein the sheet of material comprises two opposing major surfaces thatare aligned with a direction of flow of air through the aerosol chamber.11. An aerosol delivery device component according to claim 9, whereinthe sheet of material comprises two opposing ends that are attached tothe aerosol delivery device component such that the sheet of material issuspended across the aerosol chamber.
 12. An aerosol delivery devicecomponent according to claim 9, wherein the aerosol forming member isattached to at least one of the chamber walls.
 13. An aerosol deliverydevice component according to claim 9, wherein the at least onecorrugation of the sheet of material is in close proximity to at leastone of the chamber walls.
 14. An aerosol delivery device componentaccording to claim 9, wherein the at least one corrugation of the sheetof material is in contact with at least one of the chamber walls.
 15. Anaerosol delivery device component according to claim 9, wherein at leastone of the chamber walls comprises a heat shield.
 16. An aerosoldelivery device component comprising: an air inlet and an air outletfluidly communicating via an aerosol chamber defined by chamber walls,wherein at least one of the chamber walls comprises a liquid reservoirmatrix.
 17. An aerosol delivery device component according to claim 16,wherein the liquid reservoir matrix comprises a capillary structure. 18.An aerosol delivery device component according to claim 16, wherein theliquid reservoir matrix comprises a heat resistant layer and a resilientlayer.
 19. An aerosol delivery device component according to claim 18,wherein two opposing chamber walls each comprise a liquid reservoirmatrix, and the heat resistant layer of each liquid reservoir matrix isinnermost relative to the aerosol chamber such that the resilient layerurges the heat resistant layers towards one another.
 20. An aerosoldelivery device component according to claim 16, further comprising anaerosol-forming member at least partially located within the aerosolchamber.
 21. (canceled)
 22. An aerosol delivery device componentaccording to claim 20, wherein the at least one corrugation of the sheetof material is in contact with the liquid reservoir matrix.
 23. Anaerosol delivery device comprising an aerosol-forming member as claimedin claim
 1. 24. An aerosol delivery device according to claim 23comprising multiple aerosol-forming members.
 25. An aerosol deliverydevice according to claim 24 comprising multiple aerosol-forming memberspositioned in the aerosol delivery device such that the corrugations arealigned with respect to a direction of airflow through the device. 26.An aerosol delivery device according to claim 24 comprising multipleaerosol-forming members positioned in the aerosol delivery device suchthat the corrugations are off-set with respect to a direction of airflowthrough the device.
 27. An aerosol delivery device comprising an aerosoldelivery device component as claimed in claim
 9. 28. An aerosol deliverydevice comprising an aerosol delivery device component as claimed inclaim 16.